Life As a Flat Horseshoe Crab

For a class project, students researched flat pack product design. Flat pact product design is used to build furniture that can be easily taken apart and stored with a minimal amount of space when not in use. Ikea is famous for its use of flat pack product design. Based on the "Being Green" concept, students used recyclable cardboard to make costumes for middle-school aged children. Students split into groups of 4-6, and chose a theme. The horseshoe crab belongs to the shelled marine life group.

Design Brief:
My group was required to make six separate costumes, because there are six people in our group. We have chosen the theme of Shelled Marine Animals, such as horseshoe crabs, clams, and turtles. My costume is a horseshoe crab. I am required to make this using flat pack product design with cardboard.

**note, wings can be slotted in on either side, depending on preference.

Teacher Notes

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Step 1: Assembling Part 1: Base

1. Trace the shape of the piece using a ruler(T3) and a pencil(T4) onto cardboard(S1)

2. Carefully cut out the shape with a utility knife(T2). Make sure a cutting mat(T1) is underneath the spot where you are cutting!

3. Gently pop the base out of the cardboard.

4. At the top of the base, using a ruler(T3), measure two inches down from the center. Mark it with a pencil(T4)

5. Using a ruler(T3), measure an inch and a half on either side of the mark you made in step 4. Mark these spots with a pencil(T4)

6. From the marks you made in step 5, using a ruler(T3), measure down three inches, and mark with a pencil(T4). Connect the two points on either side with a line. This will create a slot for (P2).

7. Cut along the line you just made with a utility knife(T2). Again, make sure a cutting mat(T1) is underneath the spot where you are cutting.

8. Turn the base around and repeat this process on the lower half.

9. Using a ruler(T3), measure one inch in from where the slanted segment of the base meets the straight edge. Mark with a pencil(T4)

10. From the point you just marked, use a ruler(T3) to measure two inches down. Mark with a pencil(T4)

11. From the point you just marked, use a ruler(T3) to measure three inches towards the center. Mark with a pencil (T4). Connect This point to the point marked in step 10.

12. Cut along this line using a utility knife(T2)

13. Repeat steps 9-12 on the other side and bottom of the base.

14. On the bottom of the base, use a ruler(T3) to measure one inch down from the vertical slits made in steps 4-7.

15. Draw a line using a pencil(T4) three inches long, centered on the bottom of the base.

16. Cut along this line using a utility knife(T2).

Step 2: Assembling Part 2: Wings

Part P2: Wings

1. Trace the shape of the piece using a ruler(T3) and a pencil(T4) onto (S1)

2. Carefully cut out the shape with utility knife(T2). Make sure a cutting mat(T1) is underneath the spot where you’re cutting!

3. Gently pop the wing out of the cardboard.

4. On the top rectangle segment of the wing, use a ruler(T3) to measure an inch and a half in from the side, and from the bottom. Mark using a pencil(T4)

5. From the point you marked, use utility knife(T2) and cut downward. *On the second wing, make sure to make upward slits instead*

6. Flip the wing over and repeat steps 4-6 on the other rectangle segment.

7. Repeat for second wing.

Step 3: Assembling Part 3: Straps

Part P3: Straps

1. Trace the shape of the piece using a ruler(T3) and a pencil(T4) onto (S1)

2. Carefully cut out the shape with utility knife(T2). Make sure a cutting mat(T1) is underneath the spot where you are cutting!

3. Gently pop the base out of the cardboard.

4. Repeat for second strap.

Step 4: Assembling Part 4: Tail

Part P4: Tail

1. Trace the shape of the piece using a ruler(T3) and a pencil(T4) onto (S1)

2. Carefully cut out the shape with utility knife(T2). Make sure a cutting mat(T1) is underneath the spot where you are cutting!

3. Gently pop the tail out of the cardboard

Step 5: Assembling the Horseshoe Crab

If interested, i recommended you paint your cardboard, if it isn't already, brown. Most horseshoe crabs are. Barnacles also occasionally are found on the backs of shells. Gluing shells on the back would be a decorative touch.Part ListITEM QTY PART NAME
P1 1 Base
P2 2 Wings
P3 2 Straps
P4 1 Tail

1. Set the base(P1) down in front of you.

2. Insert the wings(P2) into the vertical slots on either side of the base(P1) (REPEAT)

3. Insert the tail(P4) into the horizontal slot on the bottom of the base(P1).

4. Flip over.

5. Take the slits on the rectangular segments of the wings (P2) and slot them together. This will keep the wings from falling out.

6. Insert the straps(P3) into the horizontal slits closest to the edges of the base(P1).